Note: Adjust temperatures of mixer water jacket and ingredients to achieve the finished dough temperature of 33oC which is important for maximum enzyme activity.

1.4 Standing time

After mixing, the dough is stood to allow the enzyme to react with the gluten. The standing time is about 3.5 – 4 hours at 32oC and RH 70-80%. The time must be determined carefully depending on the amount of enzyme and the quality of the flour in order to achieve the soft, delicate eating texture of the cracker.

]]>https://bakerpacific.net/2018/03/04/snack-crackers-process-and-recipes/feed/0Snack crackersbakerpacificHow to build a biscuit ovenhttps://bakerpacific.net/2018/01/04/how-to-build-a-biscuit-oven-2/
https://bakerpacific.net/2018/01/04/how-to-build-a-biscuit-oven-2/#respondThu, 04 Jan 2018 17:01:42 +0000http://bakerpacific.net/?p=1398The ovens shown below were built by contractors in China, India and Indonesia. Our team for the complete projects consisted of 5 people. The ovens were built, installed and commissioned with the minimum overhead and company cost and a large part of the manufacturing cost was incurred in local currency.

Our team built Direct Gas Fired ovens, Indirect Radiant ovens and Hybrid ovens. Many biscuit bakeries and engineering contractors could provide a similar team to build first class biscuit baking ovens to the bakery’s specification at low cost – avoiding high overheads, shipping costs and incurring a large percentage of the cost in local currency.

For more information and technical support for design and manufacturing visit:

A non-insulated temporary building that provides excellent protection for production and ambient storage. The buildings are quick and easy to transport, install, dismantle, relocate, modify and extend. Buildings have a high re-usability.

Walls: single skin steel cladding that is robust, standing up to the harshest weather

Services: doors, lighting, guttering, power distribution, flooring

Strong and durable aluminium frame with a 10 year guarantee

Snow and wind loadings to BS6399

All roof, wall and floor systems conform to British Fire & Safety codes

Temporary buildings are anchored down to level hard standing without needing foundations

A temporary storage structure is easy to extend, modify, dismantle or relocate

PVC roof provides high degree of natural light

Production equipment

The proposed biscuit line is the simplest semi-automatic production line based on a tunnel oven. The mixing and forming machines are suitable for moulded doughs, allowing a wide variety of shapes and recipes to be made. The process is widely used for nutritional biscuits in Asia, including the very popular “Biskuat” in Indonesia and “Parle G” in India, which claims to be the world’s biggest selling biscuit.

The biscuits are baked on a tunnel oven with 3 heating zones separately controlled for process control of biscuit structure, moisture level and colour. The oven is heated either by diesel oil or gas.

The production line is semi-automatic. Labour is required for weighing ingredients and feeding them to the mixer tub. The dough tub is portable and after mixing the dough is taken to the moulding machine and is fed manually. The baking and cooling are continuous and automatically controlled. Biscuits will be packed manually.

The proposed production line will produce 500 – 600 kg per hour.

Packaging

Biscuits have very low moisture contents, typically around 2%, which ensures a long shelf life. For immediate consumption, biscuits can be delivered directly from lined cartons. For biscuits which will be stored and transported, simple packaging is required, to ensure the shelf life, particularly in humid climates. Suitable materials are polypropylene, coated paper or various laminates.

After baking the biscuits are cooled to around ambient temperature on conveyors. The conveyors are arranged to “penny stack” the biscuits on to a packing table from where they are picked up by the packing staff. The biscuits may be packed directly into cartons, or transferred to the infeed conveyors of simple Flowpack wrapping machines

(estimated time following local provision of a concrete floor and services, actual time will depend on labour and services available on site)

Services (depends on the local capability)

Building 10 days

Installation of production line and start up 60 days

The building and production equipment would be “portable”, able to be rapidly dismantled, packed in containers and moved to a different site.

Service requirements for biscuit production line

Total estimated maximum power: 75 kW

Diesel oil fuel for baking: 19 kg/hour (23 litre/hour)

Compresssed air: 6-8 bar, consumption negligble

Ingredient usage

Ingredients required kg per hour kg per shift (8 hours)

Flour 356.1 2849

Dough fat 114.3 914

Sugar 88.5 708

Malt 26.4 211

Milk powder 3.1 25

Lecithin 1.9 16

Ammonium bicarbonate 1.9 16

Salt 3.8 8

Water 32.0 256

Total 628 kg 5003 kg

Production staff required

Ingredient store 4

Weighing and measuring of ingredients 2

Dough mixing 2

Feeding dough to the rotary moulder 2

Baking oven 1

Cooling / stacking 2

Packing (Flowpack) machine 6

Carton packing 5

Finished goods store / despatch 5

Engineer / supervisor 2

Total 31

Disclaimer

The information for ‘The BISKAID Project’ has been prepared by Baker Pacific Ltd from various sources. Baker Pacific Ltd has made reasonable efforts to ensure the accuracy of the information. Baker Pacific Ltd, however, does not accept any liability for the accuracy or authenticity of the information or for any errors, omissions or misinterpretation of the information. Baker Pacific Ltd does not accept any responsibility for any consequences arising from the use of information contained in this manual.

Examples of semi-sweet biscuits are Marie, Petit Buerre, Rich Tea, Arrowroot, Breakfast biscuits. They are characterised by an even, attractive colour with smooth surface sheen, light texture and good volume.

Doughs for semi-sweet biscuits have the following features:

Doughs have strong, developed gluten which gives an elastic dough, which is sheeted and cut. It often shrinks in the first stage of baking

Doughs have relatively low sugar and fat

Doughs have water contents typically of around 12%

Biscuits are normally baked on a wire-mesh band (except for Marie which is traditionally baked on a steel band)

Humidity in the first part of the baking is important to achieve good volume and a smooth surface sheen

Biscuits are baked to low moisture contents, around 1.5% – 2.0%

Critical ingredients

Medium protein flour which should not exceed 9.0% protein. Higher protein will result in a hard biscuit.

Cornflour and maize flour are used to reduce the total gluten content and make a more tender eating biscuit.

SMS will modify the protein to make a softer extensible dough

Mixing

Baker Perkins Horizontal High Speed mixer with shaft-less blade

Semi-sweet doughs are mixed with an “all in one mix” on a horizontal mixer. Mixing is critical to developing the soft extensible dough. A mixing action which kneads the dough without too much tearing and extruding is ideal.

Mixing time on a typical high speed mixer will be 20-25 minutes. Doughs such as ‘Marie’ are mixed until the required temperature is achieved. The dough should reach 40-42oC. At this temperature it should be well kneaded and of correct consistency for machining. Higher dough temperatures result in unstable doughs.

The dough is used straight away without standing and it is important to maintain the temperature.

Forming

The dough may be laminated, but doughs made with SMS are usually sheeted without lamination. Dough scrap incorporation is very important and should be very even and consistent. The temperature of the scrap dough should be as close as possible to the temperature of the new dough. Dough sheet reduction should be gentle and should not exceed the ratio of 2.5:1.

Baker Perkins rotary cutting line with 3 gauge roll units

Typical roll gaps are:

Forcing roll gap on sheeter: 18.0 mm

Gauging gap on sheeter: 9.0 mm

1st gauge roll 5.7 mm

2nd gauge roll 2.5 mm

Final gauge roll 1.1 mm (Cutting thickness: 1.3 mm)

The doughs shrink and require good relaxation before cutting. Separate cutting and printing rolls on the rotary cutter are recommended to achieve good, clear printing and docker holes, (piercing of holes in the dough pieces).

Biscuit cutting machine from Dingson Food Machinery

Baking

Direct Gas Fired and Indirect Radiant ovens are both suitable for baking semi-sweet biscuits either as individual ovens or as a Direct Gas Fired / Indirect Radiant combination oven. Convection zones may be used in the middle and final zones of the oven for drying and colouring the biscuits.

Steam may be used at the oven entry to achieve a high humidity. This will improve the surface finish of the biscuit.

New marketing report from Baker Pacific Ltd

DESCRIPTION

The report shows the very wide range of packaged snacks available in Indonesia. Indonesia, a country with over 13,600 islands in a tropical sea, tropical forests and mountain ranges which provide temperate climates for growing vegetables and fruits. This enormous variety of landscape provides an abundance of raw materials from grain, vegetable, fruit, fish, seafood and meat.

In this report we have brought together images of a wide variety of snacks and brands to give an introduction to this market. There are many original snack products, which warrant a wider consumer base in Asia and in western countries. The growing market in Indonesia for packaged snacks is an attraction for major global snack makers.

AUTHORS

Yeyen Sumarto, Mariana Ermaya, Iain Davidson

Technical Associate: Institut Pertanian Bogor

Key Features

Details of 245 Indonesian snacks, 119 pages

Product process and ingredient data

Information on special products, for example tempe, tahu, emping, melinjo, local ingredients, flavours, spices from the famed Spice Islands

Retail and pricing information

Manufacturers and distributor listings

Local knowledge and support team

Development contacts with Indonesian food technology organisations

PUBLISHER

Published as an e-book by Baker Pacific Ltd.

Price: GBP 120.00 / USD 150.00

To order or for more information contact: bakerman@bakerpacific.com.hk

252 pages

Description

The new publication will enable a small team to build high quality Direct Gas Fired ovens. The Baker Pacific team of five engineers have manufactured a range of ovens for biscuits, crackers, cookies and cake with local contractors in China, India and Indonesia. Our experience, technical information and drawings are now available for companies who wish to build Direct Gas Fired biscuit ovens.

Our book describes the complete oven building process with photos, assembly drawings and parts lists, together with descriptions of the work in 15 stages.

In addition Baker Pacific can supply a complete set of manufacturing drawings together with all detail technical information and support.

This will allow small teams in biscuit bakeries and contract engineering companies to build ovens locally. The ovens can be built in a low cost environment with minimum shipping cost and requirement for hard currency.

Key features

Description of each stage of building and installing the oven with photos

All main assembly/layout drawings

All parts lists

Key component specifications and suppliers

Detail oven specifications

Readership

Senior management staff and engineers in contract engineering companies, biscuit manufacturers and companies supplying production and baking equipment in the food industry world – wide.

Author

Iain Davidson

Iain graduated from the School of Industrial Design (Engineering) at Royal College of Art in London in 1965 and joined Baker
Perkins Ltd. He was Industrial Design Engineer, working in the Technical Department on the design of new biscuit and bakery processing machines until 1975, gaining a thorough technical knowledge of the machines and processes.

In 1975, Iain was appointed Market Development Manager at Baker Perkins, involved in developing the Baker Perkins forward planning for new business, product development and acquisitions. In 1979 Iain became International Sales Manager with responsibility for the business in Asia and Africa.

In 1990 Iain was appointed Regional Manager Asia Pacific for Baker Perkins and re-located to Indonesia and later in 1997 to China. His appointments included Managing Director of Baker Perkins (Hong Kong) Ltd. and Director of Baker Perkins Japan KK.

Iain established a successful manufacturing facility for biscuit ovens in Dalian, China in 1990 for Baker Perkins and subsequently continued a manufacturing capability for Baker Pacific Ltd. in China, India and Indonesia.

Baker Pacific companies

Iain established PT Baker Pacific Mandiri in Indonesia in 2000. As the business outside Indonesia grew, Baker Pacific Ltd was established in Hong Kong in 2004 and is now our principal operating company, providing process technology and machinery for the biscuit, chocolate and candy industries.

Experience in the biscuit industry

Engineering design of biscuit process machines including a range of baking ovens

Biscuit Baking Technology, Second Edition, is a reference book for senior managers and staff involved in industrial scale biscuit baking. It covers the biscuit industry process, ingredients, formulations, besides design, manufacture, installation, operation and maintenance of the baking ovens.

Written by an expert on the biscuit baking industry, the book is a complete manual guide that will help engineering, production and purchasing managers and staff in the biscuit industry to make the best decisions on oven efficiency purchasing.

DGF oven burners use a “zero pressure” gas system. The burners ignite and burn a gas/air mixture. The gas is supplied to the gas/air mixer unit at nominally zero pressure. The air is supplied at a positive, controlled pressure. An increase in air pressure increases the flame and the heat input to the baking chamber. The gas may be natural gas, town gas (manufactured from coal), or LPG (liquid petroleum gas).

Gas train

Mains gas is supplied from a factory system to the oven where it is regulated by a “gas train”. This consists of the following equipment:

Manual shut off valve

Two – automatic shut off valves for safety the system

Gas filter

Zero pressure gas governor

Gas pressure high/low detection

Gas pressure gauges (2) at gas inlet and outlet of gas train

Gas valve tightness proving facility (to check for a leakage of gas)

Main gas pipes and gas distribution system

The gas is fed to header pipes running along each zone of the oven at the top and bottom. The headers are connected to each burner by flexible hoses and via a solenoid valve and gas/air mixer.

Combustion air

In each zone the air is fed to the air header pipes from an air blower mounted on top of the oven. The air is drawn from the bakery and is filtered. The air pressure for the burner system is controlled by motorized valves which are regulated by the automatic temperature control system or by a variable speed inverter drive for the fan.

Moro Combustion air fan mounted on top of a DGF oven

Eratec MFB burners

MFB burners (metal-fiber burners)

Eratec high rate infra-red ribbon burners for Direct Gas Fired Ovens

Direct heat transfer by radiation (without contact and air movement)

High radiant power density 100 – 1000KW/m2

Precise control and power modulation

Energy consumption savings compared to conventional Direct Gas Fired Burners (up to 20% saving depending on the oven and number of burners)

Burners for indirect fired ovens

Each oven zone has one burner firing into a burner tube connected to a heat exchanger system. The hot air and burnt gas circulates in the heat exchanger and does not enter the baking chamber. Fuel may be gas or diesel oil. Burners may be specifies for either fuel or dual fuel.